PROCESS
ENGINEER

Process Engineer

Classification: Salary exempt

Reports to: Principal Technology Development Engineer

 

About Air Energy, Inc.

Air Energy is an energy storage platform company developing solid-state lithium-air batteries to deliver transformational improvements in energy density, safety, and mission capability for aerial and autonomous platforms and back-up AI power resilience systems.
We were founded on a simple conviction: the limits of electric flight, autonomy, and resilient power aren't set by physics — they're set by batteries. Lithium-ion technology is nearing its ceiling, and incremental gains can no longer unlock the step-change performance required for long-range drones, electric aviation, and mission-critical power systems operating far from the grid. Air Energy exists to break through that ceiling.

 

Born from a breakthrough in solid-state lithium-air science, we're pioneering a new class of batteries designed to deliver nearly 4x the energy density of today's best lithium-ion cells, while improving safety, sustainability, and system-level resilience. By eliminating the need to carry oxygen internally, our architecture dramatically reduces inactive mass — enabling lighter platforms, longer endurance, and entirely new mission profiles. This is a platform shift: it will unlock capabilities such as multi-day autonomous maritime surveillance, long-range cargo drones, persistent aerial communications, electric regional aviation, and resilient backup power for critical infrastructure and AI data centers.

 

We are execution-driven, moving from validated science to real-world cells, pilot manufacturing, and full-system integration in partnership with government and commercial leaders. Air Energy is a Public Benefit Corporation because our mission goes beyond performance metrics and financial returns — we're building foundational energy technology to catalyze energy resilience and independence at scale. For more information, visit airenergy.io.

 

Purpose of the Role

The Process Engineer will take Air Energy's cell chemistry from bench-scale demonstration to a repeatable, scalable fabrication process. You'll own the process development that turns promising lab results into a pilot line capable of building consistent, testable cells at increasing volume. From slurry properties to coating and assembly, the Process Engineer will be the in-house expert ensuring R&D-level breakthroughs are translatable to larger-scale manufacturing.

 

Core Responsibilities

• Develop and optimize slurry formulations for solid-state electrolyte membranes and cathode structures—binder/solvent systems, active material and conductive additive loading, particle dispersion, and rheology control

• Own roll-to-roll (R2R) coating process development, including slot-die/comma-coating setup, coating weight and thickness uniformity, drying profile optimization, and web handling

• Run formulation and process DOEs to map slurry rheology, coating quality, and downstream electrochemical performance, and translate results into robust, documented process windows

• Troubleshoot coating defects (streaking, pinholes, delamination, uneven drying) and drive root-cause fixes back into formulation or process parameters

• Adapt slurry and coating processes for air/moisture-sensitive solid-electrolyte and lithium-compatible materials, including dry-room and inert-atmosphere handling

• Translate R&D recipes into robust, documented processes (SOPs, work instructions, process control plans) suitable for pilot-scale production

• Specify, qualify, and troubleshoot slurry mixing and R2R coating equipment; partner with equipment vendors as needed

• Work closely with the R&D engineers on formulation handoff and with quality engineering on in-process control

• Evaluate new equipment and processing techniques for scalable manufacturing of cell components

• Support qualification efforts on new installations and manufacturing ramp up

• Lead PFMEA activities and documentation

• Support qualification of incoming materials and new vendors

• Maintain rigorous documentation and support root-cause investigations of formulation- or coating-related yield issues

 

Note: This position supports U.S. Government–funded research programs. Applicants must be U.S. persons (U.S. citizens or nationals, lawful permanent residents, or protected individuals under 8 U.S.C. 1324b(a)(3)) or be eligible for any required U.S. Government authorization before starting work.

 

Key Deliverables/Outcomes

​Success in this role will be measured by:

​

• Slurry formulations developed and locked for solid-state electrolyte membranes and cathode structures, with documented rheology and dispersion targets met

• Roll-to-roll coating process qualified with coating weight and thickness uniformity within target spec, and stable, repeatable drying profiles established

• Formulation and process DOEs completed and translated into robust, documented process windows

• Coating defects (streaking, pinholes, delamination, uneven drying) root-caused and resolved, with fixes reflected in formulation or process parameters

• SOPs, work instructions, and process control plans authored and kept current for all qualified processes

• Slurry mixing and R2R coating equipment specified, qualified, and running reliably at pilot scale

• Incoming materials and new vendors qualified on schedule

• Maintain high yield in manufacturing processes

• Formulation- and coating-related yield issues investigated and closed with documented root cause

Compensation

The target base salary range for this position is $90,000–$130,000, with placement within the range based on experience, qualifications, and level at hire. Compensation may also include equity participation and performance-based incentives, in addition to the benefits summarized below.